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Did some more testing--I think the problem was due to the PDF printer. Using PDF995 seems to work reasonably well, although the document name (same as the source file unless PDFedit995 is used to enforce a title
) and page formatting (margins wroung unless standard sizes are used) are still not optimal. At least the desired font is properly displayed, all characters show, and boldface works.
There are a lot of tools out there, obviously not all of which work. I'm sure PDF995 has its problems too, but it seems to be a reasonable starting point.
Tests on fonts show that Tireasis LP 14 point is very readable under all light conditions, with an A6 page size (slightly larger than desired, but PDF995's page sizing support seems a bit flakey). This works reasonably well with full justification, although spacing between words is a bit uneven due to the low number of words per line.
In better lighting conditions, Franklin Gothic Demi Condensed 14 point is even better, as it allows more characters per line and looks more evenly spaced. However it is a bit small and might benefit from a larger font size which would remove some of its advantages. Many fonts also have missing apostrophes and occasional kerning errors.
Main negatives to using PDF eith embedded fonts compared to RTF: page turns take at least twice as long, and files are larger (this may be less of an issue with large files, assuming the extra size is just the font). Another issue is that (at least with these PDF files) text is not reflowed, so "resizing" simply zooms in to eliminate margins, headers, and foorters. There are only two sizes that differ only slightly, not 3 like RTF files.
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